Methods and systems for battery pack thermal management

ABSTRACT

Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module, A thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries,

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application No. 62/789,110, entitled: “Methods andSystems for Battery Pack Thermal Management”, filed on Jan. 7, 2019,which is incorporated herein by reference in its entirety for allpurposes.

BACKGROUND

Various powered systems (e.g., electric vehicles) use battery packs tostore electrical energy. Performance of the batteries in these packsdepends on their temperature. For example, most lithium-Ion batterieshave a relative narrow operating range of 0-50° C. Attempting to chargeor discharge lithium-Ion batteries outside of this temperature range cancause permanent damage to the batteries and even unsafe conditions,especially when the batteries are overheated. On the other hand, thermalmanagement of battery packs is challenging, especially of large batterypacks used in electrical vehicles. In addition to environmental factors(e.g., cold or hot ambient temperatures), batteries experience internalheating during their operation, such as charge and discharge. The heat,generated inside a battery during its charge and/or discharge, isproportional to the square of the current multiplied by the internalresistance of the battery (P=I²×R). At the same time, highercharge-discharge currents are often needed for various applications,e.g., faster charging and acceleration of electrical vehicles andelectrical grid balancing, which further complicates thermal managementinside battery packs.

What is needed are methods and systems for battery pack thermalmanagement, in particular, active battery cooling and heating.

SUMMARY

Provided are methods and systems for battery pack thermal management,such as heating and cooling of individual batteries arranged intobattery packs. The methods and systems use thermal control modules,specifically configured to thermally couple to the side wall and thebottom end of each battery in a battery pack. In some examples, athermal control module comprises a thermal plate and one or two batteryengagement components, connected and thermally coupled to the thermalplate. Each battery engagement component comprises a plurality ofbattery receiving openings. When the batteries are installed into theseopenings, the side wall and the bottom end of each battery are thermallycoupled to the thermal control module, A thermal fluid is circulatedthrough at least the thermal plate to provide cooling or heating to thebatteries without any direct contact between the thermal fluid and thebatteries,

These and other examples are described further below with reference tothe figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described examples of the disclosure in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein like reference charactersdesignate the same or similar parts throughout the several views, andwherein:

FIG. 1A is a schematic cross-sectional representation of a battery pack,comprising a thermal control module and an electrical interconnectmodule, in accordance with some examples.

FIG. 1B is a schematic perspective representation of the battery pack,comprising multiple thermal control modules and electrical interconnectmodules, in accordance with some examples.

FIG. 2A is a schematic cross-sectional side view of a battery, showingvarious internal components of the battery, in accordance with someexamples.

FIG. 2B is a schematic top view of the battery of FIG. 2A, showing twocontacts, in accordance with some examples.

FIG. 3A is a schematic cross-sectional view of a thermal control module,prior to placing batteries into battery receiving openings of thethermal control module, in accordance with some examples.

FIG. 3B is a schematic top view the thermal control module of FIG. 3A,showing batteries positioned in the battery receiving openings, inaccordance with some examples.

FIG. 3C is a schematic cross-sectional view of the thermal controlmodule of FIG. 3B, showing heat transfer from the batteries to thethermal plate (and to the thermal fluid) through the battery engagementcomponent, in accordance with some examples.

FIG. 3D is a schematic cross-sectional view of another example of thethermal control module, comprising a thermal plate and two batteryengagement components.

FIG. 4A is a schematic cross-sectional view of a thermal control module,comprising a thermal plate and a battery engagement component with flowchannels extending between the thermal plate and the battery engagementcomponent, in accordance with some examples.

FIG. 4B is a schematic cross-sectional view of the thermal controlmodule of FIG. 4A, showing thermal fluid flowing through the flowchannels in the thermal plate and the battery engagement component, inaccordance with some examples.

FIG. 4C is a schematic cross-sectional view of a thermal control module,comprising a thermal plate and a battery engagement component withseparate flow channels in the thermal plate and the battery engagementcomponent, in accordance with some examples.

FIG. 5A is a schematic cross-sectional view of a thermal control module,in which a battery engagement component comprises a thermal extensionand an electrically-insulating sleeve or an electrically-insulatingcoating, in accordance with some examples.

FIG. 5B is a schematic cross-sectional view of a thermal control module,comprising a thermal plate and a battery engagement component, formed asseparate components, in accordance with some examples.

FIG. 6A is an exploded schematic view of a thermal control module,showing two portions of the thermal plate, in accordance with someexamples.

FIG. 6B is a side cross-sectional view of a thermal plate, in accordancewith some examples.

FIG. 6C is a top cross-sectional view of a thermal plate, in accordancewith some examples.

FIG. 6D is a perspective view of one portion of a thermal controlmodule, in accordance with some examples.

FIG. 6E is a perspective expanded view of a part of another portion of athermal control module, in accordance with some examples.

FIG. 7A is a schematic perspective view of a thermal control module, inaccordance with some examples.

FIG. 7B is a cross-sectional view of the thermal control module shown inFIG. 7A, in accordance with some examples.

FIG. 7C is a top view of the thermal control module of FIG. 7A, showingfluid channels in a sleeve, in accordance with some examples.

FIG. 7D is another example of fluid channels in the sleeve and thebattery engagement component, in accordance with some examples.

FIG. 8A is a schematic perspective view of a thermal control module, inwhich the sleeve is formed by a plurality of sleeve cups, in accordancewith some examples.

FIG. 8B is a schematic perspective view a sleeve cup, forming a portionof the sleeve in the thermal control module shown in FIG. 8A, inaccordance with some examples.

FIG. 9 is a schematic perspective view of a thermal control module,comprising a battery engagement component formed by a plurality oftriangular extensions, in accordance with some examples.

FIG. 10A is a schematic top view of one example of a thermal controlmodule, with a plurality of triangular extensions thermally coupled tobatteries.

FIG. 10B is a schematic top view of another example of a thermal controlmodule, with a plurality of triangular extensions thermally coupled tobatteries, in accordance with some examples.

FIG. 10C is a schematic cross-sectional side view of the thermal controlmodule of FIG. 10A, showing a sleeve extending over the plurality oftriangular extensions, in accordance with some examples.

FIG. 11A is a schematic exploded view of a thermal control module, inaccordance with some examples.

FIGS. 11B and 11C are schematic views of a sleeve of a sleeve of thethermal control module shown in FIG. 11A, in accordance with someexamples.

FIG. 12 is a process flowchart corresponding to a method of operating abattery pack comprising a thermal control module, in accordance withsome examples.

FIGS. 13A and 13B are schematic representations of an electrical vehiclecomprising a battery back, equipped with a thermal control module, inaccordance with some examples.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the presented concepts. Thepresented concepts may be practiced without some or all of thesespecific details. In other instances, well known process operations havenot been described in detail so as to not unnecessarily obscure thedescribed concepts. While some concepts will be described in conjunctionwith the specific examples, it will be understood that these examplesare not intended to be limiting.

Reference herein to “one example” or “one aspect” means that one or morefeature, structure, or characteristic described in connection with theexample or aspect is included in at least one implementation. The phrase“one example” or “one aspect” in various places in the specification mayor may not be referring to the same example or aspect.

Introduction

Large batteries packs, such as packs having capacities of at least 5kWh, at least 20 kWh, or larger, are used for many differentapplications, such as electric vehicles, electrical gridstorage/balancing, and the like. Some of these applications areassociated with large charge and/or discharge currents passing throughthe battery pack. For example, large charge currents (e.g., over 100 A,or even over 300 A) may be used to expedite charging of the battery packin an electrical vehicle. Similarly, large discharge currents (e.g.,over 1000 A) may be used during rapid accelerations of the vehicle.These electrical currents cause heating (e.g., resistive heating) ofbatteries inside the battery pack due to the internal resistance ofthese batteries. The generated heat is proportional to the square of theelectrical current (P=I²×R), which illustrates the significant effect ofthe current on heating of the batteries.

At the same time, the performance of lithium-ion batteries as well asother types of batteries is greatly impacted by the temperature of thebatteries. The operating temperature range of a battery may depend onactive materials used for battery electrodes, electrolyte composition,and overall battery design. Many types of batteries (e.g., nickelcadmium, nickel metal hydride, lithium ion) are designed to operatebetween about 0° C. and 50° C. For example, charging a lithium ionbattery at temperatures below 0° C. may result in irreversible platingof metallic lithium because of limited diffusion at the negativeelectrode at low temperatures. This lithium plating can result incapacity losses and potentially unsafe conditions. Furthermore, charginga lithium ion battery at temperatures above 50° C., especially forprolonged periods of time, may result in internal gas generation andcapacity losses. Overall, environment conditions (e.g., ambienttemperature) and operating conditions (charge/discharge currents) impactthe battery temperature and, if not managed, can result in temperaturegoing outside of the operating range.

Various thermal management methods have been used for battery packs withdifferent levels of success. Some examples include passive or forced airconvection around individual batteries, flooding batteries in dielectricfluids (e.g., oils), extending cooling passages through an array ofbatteries, and positioning a cooling plate on one side of a batteryarray. However, air cooling is generally not sufficient, especially forhigh current applications. Air has much lower heat transfer coefficientand heat capacity than liquids. Furthermore, flooded cooling, wherein abattery cases is in direct contact with a cooling liquid, requires veryspecific non-conductive liquids to prevent battery shorting through thecooling liquid. Another issue comes from non-uniformly flow of coolingliquids through complex paths formed by batteries arranged inside thebattery packs. Stagnant fluid with minimal or no flow may causeundesirable hot and cold pockets in the battery pack, which should beavoided. However, flow paths are difficult to control due to the presetdesign of the batteries (e.g., all batteries having a cylindrical shapeand being the same size) and the need to pack as many batteries aspossible into a given space (e.g., to maximize the energy density of thebattery pack).

Another method involves extending cooling passages through a batteryarray such that these passages contact side walls of cylindricalbatteries. A cooling liquid flows through these cooling passages, whilethe passages provide heat transfer between the battery side walls andthe cooling liquid. However, these passages occupy space significantamount of space inside the battery pack thereby reducing the energydensity of the pack. Furthermore, these passages are typically very longand non-straight, which presents various challenges with establishinguniform flow of cooling liquids through these passages. Finally, coolingpassages often cannot contact the entire perimeter of battery side wallsthereby limiting the thermally coupling between the batteries and thecooling passages.

Another approach involves positioning a cooling plate at one side of abattery array.

This approach relies on internal heat transfer with batteries along theheight of the batteries. Furthermore, this approach may allow directheat transfer among batteries through their side walls. Finally, athermal coupling to a small end of a battery may not provide sufficientheat transfer between this battery and the cooling plate and can causeinternal hot zones, e.g., away from the cooling plate.

Provided are methods and systems for thermal management of batterypacks, which address various deficiencies of conventional systems,described above. Specifically, a thermal control module is used andspecifically configured to thermally couple to at least a portion of theside wall and the bottom end of each battery in a battery pack. Forexample, an 18650 battery has top and bottom circular ends, each havinga surface area of about 254 mm², and a cylindrical side, having asurface area of about 3673 mm² (about 14.5 times greater than each ofthe circular ends). While the bottom end may be beneficial for thermalcoupling because of its accessibility and because of the internal heattransfer within the battery, the cylindrical side has a large availablesurface for heat transfer. Overall, thermally coupling to the side wall,in addition to the bottom end of each battery in the battery pack,provides more uniform heat transfer between the batteries and thethermal control module.

Furthermore, the methods and systems utilize thermal fluids (e.g.,liquids, gases, and combinations thereof) as heat carriers. A thermalfluid is flown through a thermal control module without directlycontacting any of batteries positioned and thermally coupled to thethermal control module. While the batteries are thermally coupled to thethermal fluid (by the thermal control module), the batteries arephysically separated and electrically isolated from the thermal fluid(also by the thermal control module). As such, there are no concernsabout the batteries being electrically shortened by the thermal fluid orthe thermal fluid causing corrosion of the batteries.

FIG. 1A is a schematic illustration of battery pack 100, in accordancewith some examples. Battery pack 100 comprises batteries 200 andelectrical interconnect module 110, interconnecting batteries 200. Asfurther described below with reference to FIG. 13B, electricalinterconnect module 110 may be connected to various electricalcomponents of a system utilizing battery pack 100. Electricalinterconnect module 110 may be connected first and second contacts ofeach battery 200 in battery pack 100. For example, electricalinterconnect module 110 comprises bus bars, contact leads, and otherlike components to form these electrical connections. Various forms ofelectrical connections of batteries 200 by electrical interconnectmodule 110 are within the scope, e.g., individual connection of eachbattery, parallel connections, in-series connections, variouscombinations of parallel and in-series connections.

Battery pack 100 also comprises thermal control module 120, thermallycoupled to batteries 200 and controlling the temperature of batteries200 during operation of battery pack 100. For example, thermal controlmodule 120 is used to prevent excessive heating of batteries 200 duringrapid charging and/or discharging. In some examples, thermal controlmodule 120 is used for heating batteries 200, e.g., when battery pack100 is operated in a cold environment. Various examples of thermalcontrol module 120 are further described below.

Battery pack 100 also comprises battery pack controller 195, whichcontrols operation of one or both electrical interconnect module 110 andthermal control module 120. For example, battery pack controller 195controls the flow rate (e.g., by controlling operation of a pump) and/orthe temperature of the thermal fluid supplied to thermal control module120 (e.g., by controlling operation of a thermostat, heater, pump,and/or other components of the overall system). In some examples,battery pack controller 195 monitors the temperature of the thermalfluid inside thermal control module 120 and/or leaving thermal controlmodule 120. Various operating examples of battery pack controller 195are described below with reference to FIG. 12.

In some examples, battery pack 100 comprises multiple thermal controlmodules 120 as, for example, is shown in FIG. 1B. Specifically, FIG. 1Billustrates two thermal control modules 120, each thermally coupled totwo arrays of batteries 200, e.g., to bottom ends and side walls of eachbattery 200 in the two arrays. FIG. 18 also illustrates four electricalinterconnect modules 110, each electrically coupled to a separate arrayof batteries 200, e.g., to top ends of each battery 200.

Referring to FIG. 1A, thermal control module 120 comprises thermal plate130 and battery engagement component 140, connected and thermallycoupled to thermal plate 130. In some examples, thermal plate 130 andbattery engagement component 140 are monolithic (e.g., fabricated as onecomponent). Alternatively, thermal plate 130 and battery engagementcomponent 140 are fabricated as separate components and then joinedtogether to form thermal control module 120.

During operation of thermal control module 120, batteries 200 arepositioned within and supported by thermal control module 120. Forexample, first ends 201, which are sometimes referred to as tops ends,of batteries 200 are electrically coupled to electrical interconnectmodule 110. Battery engagement component 140 is thermally coupled tobatteries 200 or, more specifically, to sides 203 of batteries 200. Insome examples, second ends 202, which are sometimes referred to asbottom ends, of batteries 200 are thermally coupled to thermal plate130, either directly or through battery engagement component 140.Alternatively, second ends 202 are also thermally coupled to batteryengagement component 140, Battery engagement component 140 is configuredto transfer heat between batteries 200 (e.g., sides 203 and, in someexamples, second ends 202) and thermal plate 130.

Thermal fluid 109 is circulated through at least thermal plate 130 andeither remove heat from thermal control module 120 or add heat tothermal control module 120. In some examples further described below,thermal fluid 109 also circulates through battery engagement component140. It should be noted that, batteries 200 do not have direct contactwith thermal fluid 109, thereby eliminating the risk of electricalshorts among batteries 200 through thermal fluid 109. As such, anelectrically conductive thermal fluid may be used in thermal controlmodule 120.

Thermal plate 130 is configured to provide uniform flow of thermal fluid109 along the entire length (X-axis) of thermal control module 120thereby eliminating temperature variations /cold and hot spots at leastwithin thermal plate 130. The heat transfer along the height (Z-axis) ofthermal control module 120 is provided by battery engagement component140 and, to some extent, by batteries 200. A brief description ofbatteries 200 is helpful to understand thermal dynamics inside batterypack 100.

FIG. 2A is a schematic cross-sectional view of battery 200, inaccordance with some examples. In these examples, battery 200 is acylindrical cell, having a wound arrangement of its electrodes. Specificexamples of such batteries are 18650, 20700, 21700 and 22700 cells. Thisbattery configuration is simple to manufacture and has good mechanicalstability (e.g., able to withstand high internal pressures withoutdeforming). However, other types of batteries, such as prismatic andpouch batteries are also within the scope.

Referring to FIG. 2A, battery 200 comprises first electrode 221, secondelectrode 222, and electrolyte 224. First electrode 221 and secondelectrode 222 may be referred to as a negative electrode and a positiveelectrode or as an anode and a cathode. Electrolyte 224 provides ioniccommunication/exchange between first electrode 221 and second electrode222 (e.g., allowing ions to shuttle between first electrode 221 andsecond electrode 222 during charge and discharge of battery 200).

First electrode 221 and second electrode 222 are electrically insulatedfrom each other. For example, separator 223 may be disposed betweenfirst electrode 221 and second electrode 222 to provide physicalseparation and electrical isolation of first electrode 221 and secondelectrode 222. Separator 223 comprises pores and is soaked withelectrolyte 224, thereby allowing ionic exchange through separator 223.

In some examples, first electrode 221, separator 223, and secondelectrode 222 are wound into a cylindrical structures, often referred toas a “jelly-roll”. In other examples, first electrode 221, separator223, and second electrode 222 are arrangements into a stack. Firstelectrode 221, separator 223, second electrode 222, and electrolyte 224may be referred to as internal components of battery 200.

Battery 200 also comprises case 230 and cover 232, which isolate theinternal components from the environment. For example, some internalcomponents may be sensitive to moisture and other environmentalconditions. In some examples, case 230 and cover 232 are electricallyisolated from each other, e.g., by seal 233 positioned between case 230and cover 232. In these examples, case 230 is electrically connected tofirst electrode 221 (e.g., a positive electrode or a cathode), whilecover 232 is connected to second electrode 222 (e.g., a negativeelectrode or an anode). Furthermore, in these examples, case 230 isoperable as first contact 211 of battery 200, while cover 232 isoperable as second contact 212.

Case 230 and cover 232 form first end 201, second end 202, and side 203of battery 200. Referring to FIG. 2B, which shows a top view of battery200, cover 232 forms at least a portion of first end 201 (e.g., aninside portion). Case 230 forms another portion of first end 201 (e.g.,an outside rim), As such, both electrical connections to battery 200 canbe formed at first end 201 as, for example, shown in FIG. 1A. In otherwords, first contact 211 and second contact 212 of battery 200 areavailable at first end 201, at least in this example. As noted above,electrical interconnect module 110 forms electrical connections to firstcontact 211 and also to second contact 212. When these electricalconnections are formed at first end 201, second end 202 and side 203remain available, e,g., for thermal coupling.

Referring to FIG. 2A, first electrode 221 and second electrode 222extend along the height (Z-axis) of battery 200 and are wound around thecenter axis (coinciding or parallel to Z-axis) of battery 200. Each offirst electrode 221 and second electrode 222 comprises a metal currentcollector (e.g., a metal foil), which provides good thermalconductivity. Without being restricted to any particular theory, it isbelieved that the heat transfer, at least within wound cylindrical cell,is higher along its height (along the Z-axis) than along its diameter(along the X-axis and along the Y-axis). Furthermore, first electrode221 and second electrode 222 are generally positioned closer to secondend 202 than to first end 201 due to various design considerationsassociate with sealing battery 200 as well as providing first contact211 and second contact 212. As such, second end 202 is an effectivethermal coupling location. However, the surface are of second end 202 isgenerally smaller than that of side 203 (e.g., about 14.5 times greaterfor 18650-cell as noted above). As such, side 203 is also an effectivecoupling location. As described below, thermal control module 120 isthermally coupled to both second end 202 and side 203 of each battery200.

In some examples, battery 200 is a lithium ion battery. In theseexamples, first electrode 221 comprises a lithium containing material,such as Lithium Cobalt Oxide(LiCoO₂), Lithium Manganese Oxide (LiMn₂O₄),Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO₂ or NMC), Lithium IronPhosphate(LiFePO₄), Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO₂),and Lithium Titanate (Li₄Ti₅O₁₂). Second electrode 222 comprises alithium-getter material, such graphite, silicon, or the like. However,other types of batteries are also within the scope.

Examples of Thermal Control Modules

FIG. 3A is a schematic cross-sectional view of thermal control module120, in accordance with some examples, prior to installing batteries 200into thermal control module 120. FIG. 3C is a similar view of thermalcontrol module 120 of FIG. 3A, after installing batteries 200 intothermal control module 120. Once batteries 200 are installed, thermalcontrol module 120 is used for controlling temperature of batteries 200in battery pack 100.

As noted above, thermal control module 120 comprises thermal plate 130and battery engagement component 140. Referring to FIG. 3C, batteryengagement component 140 is thermally coupled to sides 203 of batteries,while thermal plate 130 is thermally coupled to second end 202, eitherdirectly or through a portion of battery engagement component 140.Battery engagement component 140 may be also referred to first batteryengagement component 140 to distinguish from second battery engagementcomponent 170, described below with reference to FIG. 3D.

Thermal plate 130 comprises first side 131, extending along first axis121 (X-axis) and second axis 122 (Y-axis) of thermal control module 120.As shown in FIG. 3B, first axis 12.1 is perpendicular to second axis122. Thermal plate 130 also comprises second side 132, also extendingalong first axis 121 and second axis 122 of thermal control module 120.Second side 132 is offset relative to first side 131 along third axis123 (Z-axis), Third axis 123 is perpendicular to each of first axis 121and second axis 122. At least one of first side 131 or second side 132partially defines interior 129 of thermal control module 120. First side131 and second side 132 may be also referred to as a first wall and asecond wall.

FIG. 3A illustrates an example, where first side 131 and second side 132define top and bottom boundaries of interior 129. In this example,interior 129 is positioned in its entirety within thermal plate 130.However, other examples, where a portion of interior 129 extends tobattery engagement component 140, are also within the scope. Some ofthese other examples are shown FIGS. 4A -4D and described below.Overall, thermal control module 120 is designed such that all or atleast most (e.g., at least 50% based on the total flow rate or at leastabout 75% of the total flow rate or even at least about 90% of the totalflow rate) of thermal fluid 190, which is supplied to thermal controlmodule 120, flows though thermal plate 130, If any portion of thermalfluid 190 flows through first battery engagement component 140 and/orsecond battery engagement component 170, the flow rate of this portionis less than that through thermal plate 130.

Referring to FIGS. 3A-3C, thermal control module 120 also comprisesthermal fluid ports 134, configured to connect to thermal fluid linesand/or other components of the overall system. Thermal fluid ports 134allow circulation of thermal fluid 109 in and out of thermal controlmodule 120 and through interior 129 of thermal control module 120. FIG.3B illustrates an example with two thermal fluid ports 134 positionedalong the same end of thermal control module 120along the length ofthermal control module 120. One thermal fluid port 134 is used to supplythermal fluid 109 to interior 129 and may be referred to as an inletport. The other thermal fluid port 134 is used to remove thermal fluid109 from interior 129 and may be referred to as an outlet port. In someexamples, the temperature of thermal fluid 109 supplied to and/orremoved from thermal control module 120 is monitored at the inlet portand/or the outlet port. The thermal fluid lines may be connected to apump, a heat exchanger, a heater, a chiller, and other like componentsfor controlling the flow rate and the temperature of thermal fluid 109flown into interior 129 of thermal control module 120. Some examples ofthermal fluid 109 include but are not limited to synthetic oil, waterand ethylene glycol, poly-alpha-olefin oil, and the like.

Battery engagement component 140 is thermally coupled and connected tofirst side 131 of thermal plate 130. In some examples, batteryengagement component 140 and thermal plate 130 are monolithic as, forexample, is shown in FIG. 3A. Alternatively, battery engagementcomponent 140 and thermal plate 130 are initially formed as separatecomponent and then attached to each other as, for example, isschematically shown in FIG. 5B.

Battery engagement component 140 comprises plurality of batteryreceiving openings 141, extending along third axis 123 of thermalcontrol module 120. Each of plurality of battery receiving openings 141is configured to receive one of batteries 200 as, for example, shown inFIG. 3B. A set of batteries 200 received by the same battery engagementcomponent 140 may be referred to as an array of batteries 200. FIG. 3Billustrates a two-dimensional array of batteries 200, extending alongfirst axis 121 (X-axis) and second axis 122 (Y-axis). Adjacent rows ofcylindrical batteries may be offset relative to each other to increasebattery density. When thermal control module 120 comprises first batteryengagement component 140 and second battery engagement component 170,thermal control module 120 is configured to receive and thermally coupletwo separate arrays of batteries 200 as, for example, is schematicallyshown in FIG. 3D.

In some examples, the size of battery receiving openings 141 is suchthat there is a snug fit between battery receiving openings 141 andbatteries 200, providing a direct contact and thermal coupling betweenbattery engagement component 140 and batteries 200. For example, thediameter of battery receiving openings 141 may be within 1-5% of thediameter of battery 200, e.g., no more than 5% of the battery diameteror, more specifically, no more than 1%. Furthermore, in some examples,battery receiving openings 141 are formed by a compressible material(e.g., of sleeve 160, further described below) to provide conformaldirect contact between battery engagement component 140 and batteries200.

Furthermore, in some examples, battery engagement component 140 providesmechanical support to batteries 200. For example, battery engagementcomponent 140 retains batteries 200 in designed positioned and maintainsthe orientation of batteries 200 in thermal control module 120 even whenbattery pack 100 is subjected to various forces (e.g., flipped upsidedown), vibration, and the like. Once battery 200 is installed intobattery engagement component 140, the force required to remove battery200 from battery engagement component 140 may be greater than, e.g., theweight of battery 200. Overall, battery engagement component 140thermally couples batteries 200 to thermal plate 130 (and, in someexamples, to thermal fluid 109), electrically insulates batteries 200from thermal plate 130 and, more specifically, from thermal fluid 109,physically isolates batteries 200 from thermal fluid 109, and, in someexamples, mechanically supports batteries 200.

Referring to FIG. 3D, in some examples, thermal control module 120further comprises second battery engagement component 170, thermallycoupled and connected to second side 132 of thermal plate 130. Secondbattery engagement component 170 comprises second plurality of batteryreceiving openings 171, extending along third axis 123 of thermalcontrol module 120, Each of second plurality of battery receivingopenings 171 is configured to receive one of batteries 200. Secondbattery engagement component 170 thermally couples this secondplurality/second array of batteries 200 to thermal plate:130,electrically insulates batteries 200 from thermal plate 130 andphysically isolates batteries 200 from thermal fluid 109. In theseexamples, battery engagement component 140 may be referred to as firstbattery engagement component 140, in order to distinguish it from secondbattery engagement component 170. Alternatively, thermal control module120 comprises only one battery engagement component 140.

In some examples, interior 129 is only disposed within thermal plate130. As such, the thermal fluid is flown only within thermal plate 130as, for example, shown in FIG. 3C. In other words, interior 129 ofthermal control module 120 does not extend into battery engagementcomponent 140, and the thermal fluid does flow through batteryengagement component 140. The heat transfer between sides 203 ofbatteries 200 and thermal plate 130 is provided by the thermalconductivity of one or more materials forming battery engagementcomponent 140. It should be noted that the thermal conductivity ofbatteries 200 is also relied on for heat transfer along third axis 123(Z-axis) during operation of battery pack 100.

Alternatively, battery engagement component 140 may comprise pluralityof engagement module flow channels 145 as, for example, is shown inFIGS. 4A-4C. Engagement module flow channels 145 are disposed in betweenadjacent ones of plurality of battery receiving openings 141 and form aportion of interior 129 of thermal control module 120. At the same time,engagement module flow channels 145 are fluidically isolated frombattery receiving openings 141 such that the thermal fluid, provided inengagement module flow channels 145, does not come in direct contactwith batteries 200.

In more specific examples shown in FIGS. 4A and 4B, first side 131 ofthermal plate 130 comprises a plurality of thermal plate openings 320.Each thermal plate opening 320 may be aligned and in fluid communicationwith one of engagement module flow channels 145, This alignment featureprovides fluidic communication between a portion of interior 129 formedby thermal plate 130 and a portion of interior 129 formed by batteryengagement component 140. As such, the thermal fluid can flow betweenthese portions during operation of thermal control module 120 or, moregenerally, during operation of battery pack 100. For example, theportion of interior 129 formed by thermal plate 130 may provide the mainpath for the thermal fluid within thermal control module 120. The fluidthermal enters, flows within, and exists individual engagement moduleflow channels 145 thereby providing convection thermal transfer withinbattery engagement component 140, in addition to conductive thermaltransfer provided by the material forming battery engagement component140.

Referring to FIGS. 4A-4B, in some examples, engagement module flowchannels 145 is in fluidic communication with a portion of interior 129within thermal plate 130. This interior portion is positioned betweenfirst side 131 and second side 132. As noted above, this interiorportion (within thermal plate 130) provides the primary path for thethermal fluid, at least along first axis 121 (X-axis) and second axis122 (Y-axis). This interior portion also sends some thermal fluid intoextension fluid channels 155 thereby establishing convective heattransfer along third axis 123 (Z-axis) when the thermal fluid flowswithin extension fluid channels 155. In some examples, engagement moduleflow channels 145 may not be directly connected with each other,Instead, each engagement module flow channels 145 receives anddischarges the thermal fluid into this portion of interior 129.

Alternatively, as for examples shown in FIG. 4C, engagement module flowchannels 145 are isolated from with this portion of interior 129,positioned between first side 131 and second side 132. Instead,extension fluid channel 155 extends at least along first axis 121 andcomprises extension fluid ports 156. As such, interior 129 may be formedby two separate portions, one within thermal plate 130 and one withinthermal extension 150. These separate interior portions may not be influidic communication with each other, at least directly. Fluidicseparation of these portions allows for independent flow control of thethermal fluid in each portion, providing additional level of the overallprocess control.

Referring to FIG. 5A, in some examples, battery engagement component 140comprises thermal extension 150 and sleeve 160. In these examples, theprimary function of thermal extension 150 may be mechanical support tobatteries 200 and to sleeve 160 as well as the heat transfer, while theprimary function of sleeve 160 may be electrical isolation of batteries200 from thermal extension 150. The addition of sleeve 160 to thermalextension 150 allows using various electrically conductive materials forthermal extension 150, such as metals or, more specifically, copper,aluminum, and the like. These materials have high thermal conductivity.

Sleeve 160 is formed from a thermally-conductive polymer or coating,which is electrically insulating. Some examples of materials suitablefor sleeve 160 are polymers with non-conductive ceramic filers, e.g.,boron nitride and aluminum nitride. In some examples, the thermalconductivity of a material forming sleeve 160 is at least about 0.5 W/mKor even at least about 2 W/mK. The electrical conductivity of a materialforming sleeve 160 is less than 10¹⁵ S/m or even less than less than10⁻¹⁵ S/m.

Sleeve 160 forms at least a portion of each battery receiving opening141. As such, in some examples, when batteries 200 are installed intothermal control module 120, only sleeve 160 (out of components ofthermal control module 120) contacts batteries 200. Sleeve 160electrically insulates thermal extension 150 from batteries 200, therebypreventing shortening of batteries 200 by thermal extension 150. At thesame time, sleeve 160 thermally couples thermal extension 150 tobatteries 200, thereby providing a thermal path from batteries 200 tothermal extension 150. In some examples, the thickness of sleeve 160 isbetween about 0.5 mm and 5 mm or, more specifically, between 1 mm and 3mm.

Referring to FIG. 5A, sleeve 160 may extend to thermal plate 130 and, insome examples, form the bottom of each battery receiving opening 141. Inthese examples, sleeve 160 also electrically insulates batteries 200from thermal plate 130, which allows forming thermal plate 130 fromelectrically conductive materials, such as metals or, more specifically,copper, aluminum, and the like.

Also, referring to FIG. 5A, thermal extension 150 directly interfacesfirst side 131 of thermal plate 130 thereby providing direct thermaltransfer and mechanical support between thermal extension 150 andthermal plate 130. In some examples, thermal extension 150 is welded,braised, soldered, or otherwise attached to thermal plate 130.Alternatively, thermal extension 150 is monolithic with thermal plate130, e.g., formed from the same initial block of material.

Referring to FIG. 5B, in some examples, battery engagement component 140and thermal plate 130 are made from different components and laterjoined together to form thermal control module 120. For example, batteryengagement component 140 may be formed from a thermally conductivepolymer, while thermal plate 130 is formed from a metal. Variousexamples of suitable thermally conductive polymers are listed above.

Various examples and features of thermal plate 130 will now be describedwith reference to FIGS. 6A-6E. In the illustrated example, first portion133 of thermal plate 130 is monolithic with first battery engagementcomponent 140, while second portion 137 of thermal plate 130 ismonolithic with second battery engagement component 170. For example,first portion 133 of thermal plate 130 and first battery engagementcomponent 140 are fabricated as a single component, which is then joinedtogether with second portion 137 of thermal plate 130 and second batteryengagement component 170, e.g., during assembly of thermal controlmodule 120, e.g., welded, braised, soldered, or otherwise attached.However, various features of thermal plate 130, which are shown anddescribed with reference to FIGS. 6A-6E, are also applicable to otherintegration examples of thermal plate 130 and one or more batteryengagement components, which are described above.

As noted above, thermal plate 130 forms at least a portion of interior129 of thermal control module 120. Furthermore, thermal plate 130 is themain carrier of thermal fluid 109 in thermal control module 120 or, insome examples, the only carrier of thermal fluid 109. Thermal plate 130also supports and is thermally coupled to one or two battery engagementcomponents (or integrated with one or two battery engagementcomponents).

Referring to FIG. 6A, in some examples, thermal plate 130 comprises aplurality of diffusers 135 disposed within interior 129 or at least aportion thereof. Diffusers 135 are supported by at least one of firstside 131 or second side 132. Diffusers 135 are configured to redirectthe thermal fluid within interior 129 thereby ensuring the uniform flowof the thermal fluid and avoiding cold and hot spots, associated withthe stagnant or excessively fast-slowing thermal fluid. Diffusers 135are configured to redirect the thermal fluid flowing along first axis121 (X-axis) at least along second axis 122 (Y-axis). It should be notedthat the main flowing direction of the thermal fluid within interior 129is along first axis 121 (X-axis).

In some examples, diffusers 135 extend between and contacts each offirst side 131 and second side 132 as, for examples, is shown in FIG.6B. For example, diffusers 135 may be attached to or monolithic with oneof first side 131 or second side 132 and contact the other side. Inthese examples, diffusers 135 act as heat spreaders between first side131 and second side 132 thereby ensuring temperature uniformity withininterior 129, in addition to the thermal fluid. Furthermore, diffusers135 may provide mechanical support to first side 131 and second side 132(e.g., relative to each other such as transfer forces between first side131 and second side 132). This feature allows forming first side 131 andsecond side 132 with thinner walls thereby reducing the weight andimproving thermal transfer of thermal control module 120,

Referring to FIG. 6C, in some examples, each of plurality of diffusers135 comprises diffusing surface 310, having an acute angle relative tofirst axis 121. Diffusing surface 310 is configured to redistribute thethermal fluid within the X-Y plane, e.g., redirects the thermal fluidflowing along first axis 121 (X-axis).

In some examples, thermal plate 130 comprises divider 136, extendingalong third axis 123 (Z-axis) as, for example, shown in FIGS. 6D and 6E.When thermal plate 130 is assembled, divider 136 extends between firstside 131 and second side 132. Furthermore, divider 136 extends, alongfirst axis 121 (X-axis), most of the thermal plate length. Specifically,divider 136 extends to the edge of thermal plate 130 containing thethermal fluid ports 134, but not to the opposite edge, thereby creatinga gap with the opposite edge. Divider 136 separates at least a portionof interior 129 (within thermal plate 130) into first part 331 andsecond part 332. This separation prevents the thermal fluid to transferbetween first part 331 and second part 332, other than through the gapbetween divider 136 and the opposite edge of thermal plate 130, therebyforcing the thermal fluid to travel the entire length of thermal plate130.

One of thermal fluid ports 134, e.g., an inlet, is in fluidiccommunication with first part 331, while another one of thermal fluidports 134, e.g., an outlet, is in fluidic communication with second part332. As such, when the thermal fluid is supplied through the inlet intofirst part 331, the thermal fluid flows through first part 332 theentire length of thermal plate 130 before returning back, through thegap between divider 136 and the opposite edge, to the outlet. Duringthis return, the thermal fluid flows through second part 332, also theentire length of thermal plate 130. Overall, divider 136 ensures thatthe thermal fluid reaches various parts of interior 129.

Referring to FIGS. 7A and 7C, in some examples, thermal extension 150comprises first extension portion 151 and second extension portion 152,both extending along first axis 121 of thermal control module 120. Firstextension portion 151 and second extension portion 152 may be individualcomponents, independently connected to thermal plate 130. Firstextension portion 151 and second extension portion 152 form extensionchannel 153, between first extension portion 151 and second extensionportion 152. In these examples, some battery receiving openings 141 arepositioned within extension channel 153.

Sleeve 160 extends into channel 153 and prevents at least direct contactbetween the batteries and thermal fluid. As shown in FIGS. 7A and 7B,sleeve 160 comprises first sleeve portion 161, disposed in extensionchannel 153 and attached to first extension portion 151. Sleeve 160 alsocomprises second sleeve portion 162, disposed in extension channel 153and attached to second extension portion 152. In this example, firstextension portion 151 and second extension portion 152 provide supportto first sleeve portion 161 and second sleeve portion 162, respectively.First sleeve portion 161 and second sleeve portion 162 are optional and,in some examples, the thermal fluid directly contacts first extensionportion 151 and second extension portion 152 of thermal extension 150.

Referring to FIGS. 7A-7C, in some examples, sleeve 160 comprises thirdsleeve portion 163, forming battery receiving openings 141. In theseexamples, sleeve fluid channel 165 extends between third sleeve portion163 and each of first sleeve portion 161 and second sleeve portion 162.Sleeve fluid channel 165 is a specific example of module flow channels145. In more specific examples, shown in FIG. 7B, sleeve 160 furthercomprises fourth sleeve portion 164, attached to first side 131 ofthermal plate 130. Sleeve fluid channel 165 extends between third sleeveportion 162 and fourth sleeve portion 164.

Furthermore, extension channel 153 comprises bridging portion 199,disposed and extending between two adjacent battery receiving openings141 as, for example, schematically shown in FIGS. 7C and 7D. Bridgingportion 199 allows positioning sleeve 160 that is continuous (at leastwithin each extension channel 153). The same sleeve may extend along thelength of battery engagement component 140, within each extensionchannel 153, and define multiple battery receiving openings 141.Furthermore, bridging portion 199 may be used to access sides 203 ofbatteries 200 during installation and removal of batteries 200 fromthermal control module 120.

Referring to FIG. 7D, in some examples, thermal extension 150 comprisesextension fluid channel 155, configured to receive the thermal fluid.Extension fluid channel 155 is specific examples of module flow channels145. Providing the thermal fluid within thermal extension 150 helps withheat transfer between batteries 200 and the thermal fluid. Specifically,without extension fluid channels 155 (and also without sleeve fluidchannels 165), the only heat transfer from the sides of batteries 200 tothermal plate 130 is conductive heat transfer provided by the material,forming thermal extension 150. Extension fluid channel 155 also addsconvective heat transfer when the thermal fluid flows within extensionfluid channel 155.

Referring to FIG. 8A, width 154 of extension channel 153, measured alongsecond axis 122 (Y-axis) of thermal control module 120, may be variable.In other words, the measurements of width 154 differ at differentpositions within extension channel 153, along first axis (X-axis).Specifically, extension channel 153 comprises a plurality of channelopenings 198, each corresponding to one of the plurality of batteryreceiving openings 141. Two adjacent channel openings 198 are separatedby bridging portion 199. Bridging portion 199 has a smaller width thanchannel openings 198. In some examples, width 154 of extension channel153 has the highest value at channel openings 198 or, more specifically,at the center of each channel opening 198. Varying width 154 ofextension channel 153 allows increasing thermal coupling between batteryengagement component 140 and batteries 200. Specifically, the interfacearea (either direct or through sleeve 160) between battery engagementcomponent 140 and batteries 200 is increased when channel openings 198have the same shape as batteries 200, e.g., circular shape within theX-Y cross-section. For example, the interface portion between batteryengagement component 140 and each battery 200 may represent betweenabout 50% and 90% of the side surface area of each battery 200 or, morespecifically, between about 60% and 80%.

Referring to FIGS. 8A and 8B, in some examples, sleeve 160 comprises aplurality of sleeve cups 169, separated from each other. Each sleeve cup169 is inserted into one of plurality of channel openings 198. Onceinserted, each sleeve cup 169 defines one of plurality of batteryreceiving openings 141. In some examples, sleeve cup 169 is firstinstalled onto battery 200. Then, this assembly, including battery 200and sleeve cup 169, is inserted as a unit into one of channel openings198. This feature simplifies fabrication of sleeve 160 as well asinstallation of sleeve 160,

Referring to FIG. 9, in some examples, thermal extension 150 comprisesplurality of triangular extensions 157, each connected or otherwiseintegrated to first side 131 of thermal plate 130. At least threetriangular extensions 157 define each battery receiving opening 141 as,for example, is shown in FIG. 10A. In this example, battery 200,positioned into battery receiving opening 141 is in thermalcommunication with three triangular extensions 157. Furthermore, thebottom end of battery 200 may be in direct thermal communication withfirst side 131 of thermal plate 130,

FIG. 10B illustrates an example, in which six triangular extensions 157define each battery receiving opening 141. Specifically, FIG. 10Billustrates battery 200, positioned in battery receiving opening 141 andin thermal communication with all six triangular extensions 157. Itshould be also noted that some triangular extensions 157, may eachdefine multiple battery receiving openings 141 and may be thermallycoupled to multiple batteries 200. For example, triangular extension157, identified with an arrow in FIG. 10B, is thermally coupled to threebatteries 200,

Referring to FIGS. 10A and 10B, in some examples, each of plurality oftriangular extensions 157 has at least two curved sides 158. In morespecific examples, each of plurality of triangular extensions 157 hasthree curved sides 158. Each curved side 158 is configured to conform toside 203 of battery 200. In some examples, the curvature radius of eachof at least two curved side 158 of each of plurality of triangularextensions 157 is between 1-10% greater than radius of each of batteries200.

Referring to FIG. 10C, in some examples, sleeve 160 fully covers each ofplurality of triangular extensions 157. Furthermore, sleeve 160 may atleast partially extend to first side 131 of thermal plate 130, therebyforming a sleeve spacer in each of plurality of battery receivingopening 141. The sleeve spacer prevents direct contact between thermalplate 130 and battery 200 when battery 200 is installed into batteryreceiving opening 141. More specifically, first side 131 of thermalplate 130 comprises plurality of exposed portions 139. Exposed portions139 is not covered by sleeve 160. It should be noted that a portion ofsleeve 160 may cover a portion of first side 131. Exposed portions 139are positioned between these covered portions. In some examples, eachexposed portion 139 is concentric with one of plurality of batteryreceiving openings 141.

FIG. 11A is a schematic exploded view of thermal control module 120, inaccordance with some examples. Similar to the example described abovewith reference to FIG. 6A, in this example, thermal plate 130 comprisesfirst portion 133 and second portion 137. Each of these portionscomprises triangular extensions 157 and a corresponding sleeve block,which is inserted onto triangular extensions 157. Specifically, theoverall sleeve 160 of thermal control module 120 comprises first sleeveblock 167, which is inserted onto triangular extensions 157 of firstportion 133, when thermal control module 120 is assembled, and secondsleeve block 168, which is inserted onto triangular extensions 157 ofsecond portion 137. Each of these sleeve blocks comprises plurality ofbattery receiving openings 141 as, for example, more clearly shown inFIG. 11B. Battery receiving openings 141 are open on top surfaces of thesleeve blocks, which face away from thermal plate 130. In some examples,battery receiving openings 141 are open on top surfaces of the sleeveblocks, which face away from thermal plate 130. The bottom of eachbattery receiving openings 141 may be formed by the corresponding sleeveblock to prevent direct contact between batteries 200 and thermal plate130. Furthermore, each of these sleeve blocks comprises plurality ofextension receiving openings 166 as, for example, more clearly shown inFIG. 11C. Triangular extensions 157 extend into extension receivingopenings 166, when thermal control module 120 is assembled.

Operating Examples

FIG. 12 is a process flowchart corresponding to method 1200 of operatingof battery pack 100, comprising thermal control module 120, inaccordance with some examples. Various examples of thermal controlmodule 120 are described above. Some operations of method 1200 may beperformed by battery pack controller 195.

Method 1200 may commence with determining the temperature of the thermalfluid (block 1210). The temperature of the thermal fluid isrepresentative of the battery temperature because of thermal couplingbetween batteries 200 and the thermal fluid, provided by thermal controlmodule 120. The temperature of the thermal fluid may be measured insidethermal control module 120 (e.g., a thermocouple positioned withininterior 129) or at one of thermal fluid ports 134, e.g., an exitthermal fluid port. This temperature determining operation may beperformed continuously during operation of battery pack 100.

Method 1200 may proceed with determining thermal fluid conditions (block1220). Some examples of these conditions are one or more flow rates ofthe thermal fluid through thermal control module 120 (or, morespecifically, through individual components of thermal control module120 when the thermal fluid is independently directed through multiplecomponents) and the temperature of the thermal fluid supplied intothermal control module 120. In some examples, these thermal fluidconditions are determined based on the temperature of the thermal fluiddetermined during the operation discussed above and represented by block1210. Furthermore, these thermal fluid conditions may be determinedbased on electrical operating conditions associated with battery pack100. For example, if a high current is being passed through battery pack100 (e.g., during its charge or discharge) or will be passed in nearfuture, the thermal fluid conditions may be adjusted preemptively, e.g.,even before the outgoing thermal fluid temperature reflects theseelectrical operating conditions.

Method 1200 also involves flowing the thermal fluid through thermalcontrol module 120 (block 1230). This operation is performed inaccordance with the thermal fluid conditions determined during theoperation discussed above and represented by block 1220. Either batterypack 100 or a facility (e.g., an electrical vehicle) where battery pack100 is installed may be equipped with various components, such as apump, a heater, and/or a chiller for pumping, heating, and/or coolingthe thermal fluid before supplying the thermal fluid to thermal controlmodule 120. These components may form a continuous loop with thermalcontrol module 120 such that the thermal fluid, existing thermal controlmodule 120, is heated or cooled and pumped back into thermal controlmodule 120. These components may be controlled by battery packcontroller 195 and may be used for other operations, e.g., such asheating or cooling the interior of an electrical vehicle.

Electrical Vehicle Examples

Some examples of thermal control module 120 and battery pack 100,comprising one or more thermal control modules 120, can be deployed inelectrical vehicles or, more specifically, hybrid electric vehicles,plug-in hybrid electric vehicles, and all-electric vehicles. Forexample, FIGS. 13A and 13B are schematic illustration of electricvehicle 250, which comprises battery pack 100 and vehicle modules 260.Some examples of vehicle modules 260 are heating module 262, coolingmodule 264, inverter 266, and motor 268 as, for example, schematicallyshown in FIG. 13B. Heating module 262 and/or cooling module 264 may beused for heating and cooling of the interior of electric vehicle 250. Insome examples, heating module 262 and/or cooling module 264 isfluidically coupled to thermal fluid ports of thermal control module120, provided in battery pack 100. The heating fluid is controllablypumped between interior 129 of thermal control module 120 and one orboth of heating module 262 and/or cooling module 264. As such, heatingmodule 262 and cooling module 264 may be used for controlling thetemperature of the thermal fluid. Inverter 266 and motor 268 may becoupled to electrical interconnect module 110 of battery pack 100, suchthat battery pack 100 is configured to supply and receive the electricalpower to/from inverter 266 and motor 268. In some examples, battery pack100 also supplies electrical power to heating module 262 and/or coolingmodule 264.

Further Examples

Further, description includes examples according to following clauses:

Clause 1. Thermal control module 120 for controlling temperature ofbatteries 200 in battery pack 100, thermal control module 120comprising:

thermal plate 130, comprising:

-   -   first side 131, extending along first axis 121 and second axis        122 of thermal control module 120, wherein first axis 121 is        perpendicular to second axis 122;    -   second side 132, extending along first axis 121 and second axis        122 of thermal control module 120 and being offset relative to        first side 131 along third axis 123, perpendicular to each of        first axis 121 and second axis 122, wherein at least one of        first side 131 or second side 132 at least partially defines        interior 129 of thermal control module 120;    -   thermal fluid ports 134, configured to connect to thermal fluid        lines and flow thermal fluid 109 in and out of interior 129 of        thermal control module 120; and

first battery engagement component 140, thermally coupled and attachedto first side 131 of thermal plate 130 and comprising plurality ofbattery receiving openings 141, extending along third axis 123 ofthermal control module 120,

-   -   wherein each of plurality of battery receiving openings 141 is        configured to receive one of batteries 200, such that first        battery engagement component 140 thermally couples batteries 200        to thermal plate 130, electrically insulates batteries 200 from        thermal plate 130, and fluidically isolates batteries 200 from        thermal fluid 109.

Clause 2. Thermal control module 120 of clause 1, wherein:

thermal plate 130 comprises plurality of diffusers 135 disposed withininterior 129 and supported by at least one of first side 131 or secondside 132,

plurality of diffusers 135 are configured to redirect thermal fluidthrough interior 129 at least along second axis 122.

Clause 3. Thermal control module 120 of clause 2, wherein each ofplurality of diffusers 135 extends between and contacts each of firstside 131 and second side 132.

Clause 4. Thermal control module 120 of any one of clauses 2 3, whereineach of plurality of diffusers 135 comprises a diffusing surface 310,having an acute angle relative to first axis 121.

Clause 5. Thermal control module 120 of clause 4, wherein the acuteangle differs for at least two of the plurality of diffusers (135).

Clause 6. Thermal control module 120 of any one of clauses 1-5, wherein:

first battery engagement component 140 comprises plurality of engagementmodule flow channels 145, disposed among plurality of battery receivingopenings 141, such that plurality of engagement module flow channels 145are fluidically isolated from plurality of battery receiving openings141,

first side 131 comprises plurality of thermal plate openings 320, eachbeing aligned and in fluid communication with one of plurality ofengagement module flow channels 145 such that plurality of engagementmodule flow channels 145 form portion of interior 129 of thermal controlmodule 120,

Clause 7. Thermal control module 120 of clause 6, wherein thermal plate130 comprises plurality of diffusers 135, each being aligned with one ofplurality of thermal plate openings 320 and configured to direct thermalfluid into one of plurality of thermal plate openings 320.

Clause 8. Thermal control module 120 of any one of clauses 1-7, wherein:

thermal plate 130 comprises divider 136, extending along third axis 123between first side 131 and second side 132 also along first axis 121thereby separating at least a portion of interior 129 into first part331 and second part 332,

one of thermal fluid ports 134 is in fluidic communication with firstpart 331, and

another one of thermal fluid ports 134 is in fluidic communication withsecond part 332.

Clause 9. Thermal control module 120 of any one of clauses 1-8, whereinboth of thermal fluid ports 134 are positioned on the same end ofthermal plate 130 along first axis 121.

Clause 10. Thermal control module 120 of any one of clauses 1-9,wherein:

first battery engagement component 140 comprises thermal extension 150and sleeve 160,

thermal extension 150 is formed from a metal,

sleeve 160 is formed from a thermally-conductive polymer or a thermallyconductive coating, and

sleeve 160 forms at least a portion of each of plurality of batteryreceiving openings 141.

Clause 11. Thermal control module 120 of clause 10, wherein thermalextension 150 comprises first extension portion 151 and second extensionportion 152, both extending along first axis 121 of thermal controlmodule 120 and forming extension channel 153 between first extensionportion 151 and a second extension portion 152.

Clause 12. Thermal control module 120 of clause 11, wherein extensionchannel 153 extends to and at least partially formed by first side 131of thermal plate 130.

Cause 13. Thermal control module 120 of clause 12, wherein width 154 ofextension channel 153, measured along second axis 122 of thermal controlmodule 120, is variable.

Clause 14. Thermal control module 120 of clause 12, wherein extensionchannel 153 comprises plurality of channel openings 155, each definingone of plurality of battery receiving openings 141 and each having thediameter corresponding to the highest value of to width 154 of extensionchannel 153.

Clause 15. Thermal control module 120 of clause 14, wherein:

sleeve 160 comprises plurality of sleeve cups 169, separated from eachother; and

each of plurality of sleeve cups 169 is inserted into one of pluralityof channel openings 155 and defining one of plurality of batteryreceiving openings 141.

Clause 16. Thermal control module 120 of clause 10, wherein thermalextension 150 comprises extension fluid channel 155, configured toreceive thermal fluid.

Clause 17. Thermal control module 120 of clause 16, wherein extensionfluid channel 155 is in fluidic communication with a portion of interior129 positioned between first side 131 and second side 132.

Clause 18. Thermal control module 120 of clause 16, wherein extensionfluid channel 155 is isolated from with a portion of interior 129positioned between first side 131 and second side 132, and whereinextension fluid channel 155 extends along first axis 121, and comprisesextension fluid ports 156.

Clause 19. Thermal control module 120 of any one of clauses 10-18,wherein thermally-conductive polymer of sleeve 160 comprises ceramicfiller.

Clause 20. Thermal control module 120 of any one of clauses 10-19,wherein sleeve 160 entirely forms each of plurality of battery receivingopenings 141.

Clause 21. Thermal control module 120 of any one of clauses 10-20,wherein sleeve 160 comprises first sleeve portion 161 and second sleeveportion 163, forming a sleeve fluid channel 165, configured to receivethermal fluid.

Clause 22. Thermal control module 120 of clause 21, wherein sleeve fluidchannel 165 is in fluidic communication with a portion of interior 129disposed between first side 131 and second side 132.

Clause 23. Thermal control module 120 of clause 21, wherein sleeve fluidchannel 165 is isolated from a portion of interior 129 disposed betweenfirst side 131 and second side 132.

Clause 24. Thermal control module 120 of clause 21, wherein:

thermal extension 150 comprises first extension portion 151 and secondextension portion 152, both extending along first axis 121 of thermalcontrol module 120 and forming extension channel 153 between firstextension portion 151 and a second extension portion 152, first sleeveportion 161 is disposed in extension channel 153 and attached to firstextension portion 151, and

second sleeve portion 162 is disposed in extension channel 153 andattached to second extension portion 152.

Clause 25. Thermal control module 120 of clause 21, wherein:

sleeve 160 further comprises third sleeve portion 163, forming at leastportion of each of plurality of battery receiving openings 141, and

sleeve fluid channel 165 extends between third sleeve portion 162 andeach of first sleeve portion 161 and second sleeve portion 162.

Clause 26. thermal control module 120 of clause 25, wherein:

sleeve 160 further comprises fourth sleeve portion 164, attached tofirst side 131 of thermal plate 130, and

sleeve fluid channel 165 extends between third sleeve portion 162 andfourth sleeve portion 164.

Clause 27. Thermal control module 120 of clause 10, wherein:

thermal extension 150 comprises plurality of triangular extensions 157,each connected to first side 131 of thermal plate 130; and

at least three of plurality of triangular extensions 157 defining eachof plurality of battery receiving openings 141.

Clause 28. Thermal control module 120 of clause 27, wherein each ofplurality of triangular extensions 157 has at least two curved sides158.

Clause 29. Thermal control module 120 of any one of clauses 27-28,wherein sleeve 160 fully covers each of plurality of triangularextensions 157 and at least partially extends to first side 131 ofthermal plate 130 forming a sleeve spacer in each of plurality ofbattery receiving openings 141.

Clause 30. Thermal control module 120 of clause 29, wherein first side131 of thermal plate 130 comprises a plurality of exposed portions 139,wherein each of plurality of exposed portions 139 is concentric with oneof plurality of battery receiving openings 141.

Clause 31. Thermal control module 120 of any one of clauses 1-30,wherein thermal plate 130 and first battery engagement component 140 aremonolithic.

Clause 32. Thermal control module 120 of any one of clauses 1-31,wherein each of plurality of battery receiving openings 141 isconfigured to snuggly fit one of batteries 200.

Clause 33. Thermal control module 120 of any one of clauses 1-32,further comprising second battery engagement component 170, thermallycoupled and connected to second side 132 of thermal plate 130 andcomprising second plurality of battery receiving openings 171, extendingalong third axis 123 of thermal control module 120, wherein each ofsecond plurality of battery receiving openings 171 is configured toreceive one of batteries 200, such that second battery engagementcomponent 170 thermally couples batteries 200 to thermal plate 130,electrically insulates batteries 200 from thermal plate 130, andfluidically isolates batteries 200 from thermal fluid.

Clause 34. Thermal control module 120 of clause 33, wherein:

thermal plate 130 and first battery engagement component 140 aremonolithic,

thermal plate 130 and second battery engagement component 170 aremonolithic, and

first side 131 and second side 132 of thermal plate 130 are joinedtogether thereby forming interior 129 of thermal control module 120.

Clause 35. Thermal control module 120 of clause 33, wherein each offirst battery engagement component 140 and second battery engagementcomponent 170 comprises insulating coating, electrically insulatingbatteries 200 from thermal plate 130.

Conclusion

Different examples and aspects of apparatus and methods are disclosedherein that include a variety of components, features, andfunctionality. It should be understood that various examples and aspectsof apparatus and methods disclosed herein may include any of components,features, and functionality of any of other examples and aspects ofapparatus and methods disclosed herein in any combination, and all ofsuch possibilities are intended to be within spirit and scope of presentdisclosure.

Many modifications and other examples of disclosure set forth hereinwill come to mind to one skilled in art to which disclosure pertainshaving benefit of teachings presented in foregoing descriptions andassociated drawings,

Therefore, it is to be understood that disclosure is not to be limitedto specific examples presented and that modifications and other examplesand aspects are intended to be included within scope of appended claims.Moreover, although foregoing descriptions and associated drawingsdescribe examples in context of certain illustrative combinations ofelements and/or functions, it should be appreciated that differentcombinations of elements and/or functions may be provided by alternativeimplementations without departing from scope of appended claims.

What is claimed is:
 1. A thermal control module for controllingtemperature of batteries in a battery pack, the thermal control modulecomprising: a thermal plate, comprising: a first side, extending along afirst axis and a second axis of the thermal control module, wherein thefirst axis is perpendicular to the second axis; a second side, extendingalong the first axis and the second axis of the thermal control moduleand being offset relative to the first side along a third axis,perpendicular to each of the first axis and the second axis, wherein atleast one of the first side or the second side at least partiallydefines an interior of the thermal control module; thermal fluid ports,configured to connect to thermal fluid lines and flow a thermal fluid inand out of the interior of the thermal control module; and a firstbattery engagement component, thermally coupled and connected to thefirst side of the thermal plate and comprising a plurality of batteryreceiving openings, extending along the third axis of the thermalcontrol module, wherein each of the plurality of battery receivingopenings is configured to receive one of the batteries, such that thefirst battery engagement component thermally couples the batteries tothe thermal plate, electrically insulates the batteries from the thermalplate, and fluidically isolates the batteries from the thermal fluid. 2.The thermal control module of claim 1, wherein: the thermal platecomprises a plurality of diffusers disposed within the interior andsupported by at least one of the first side or the second side, theplurality of diffusers are configured to redirect the thermal fluidthrough the interior at least along the second axis.
 3. The thermalcontrol module of claim 2, wherein each of the plurality of diffuserscomprises a diffusing surface, having an acute angle relative to thefirst axis.
 4. The thermal control module 3, wherein the acute anglediffers for at least two of the plurality of diffusers.
 5. The thermalcontrol module of claim 1, wherein: the thermal plate comprises adivider, extending along the third axis between the first side and thesecond side also along the first axis thereby separating at least aportion of the interior into a first part and a second part, one of thethermal fluid ports is in fluidic communication with the first part, andanother one of the thermal fluid ports is in fluidic communication withthe second part.
 6. The thermal control module of claim 1, wherein bothof the thermal fluid ports are positioned on a same end of the thermalplate along the first axis.
 7. The thermal control module of claim 1,wherein: the first battery engagement component comprises a thermalextension and a sleeve, the thermal extension is formed from a metal,the sleeve is formed from a thermally-conductive polymer or athermally-conductive coating, and the sleeve forms at least a portion ofeach of the plurality of battery receiving openings.
 8. The thermalcontrol module of claim 7, wherein the thermal extension comprises afirst extension portion and a second extension portion, both extendingalong the first axis of the thermal control module and forming anextension channel between the first extension portion and the secondextension portion.
 9. The thermal control module of claim 8, wherein theextension channel extends to and at least partially formed by the firstside of the thermal plate.
 10. The thermal control module of claim 8,wherein a width of the extension channel, measured along the second axisof the thermal control module, is variable.
 11. The thermal controlmodule of claim 10, wherein the extension channel comprises a pluralityof channel openings, each defining one of the plurality of batteryreceiving openings and each having a diameter corresponding to a highestvalue of to the width of the extension channel.
 12. The thermal controlmodule of claim 11, wherein: the sleeve comprises a plurality of sleevecups, separated from each other; and each of the plurality of sleevecups is inserted into one of the plurality of channel openings anddefining one of the plurality of battery receiving openings.
 13. Thethermal control module of claim 7, wherein: the thermal extensioncomprises a plurality of triangular extensions, each connected to thefirst side of the thermal plate; and at least three of the plurality oftriangular extensions defining each of the plurality of batteryreceiving openings.
 14. The thermal control module of claim 13, whereineach of the plurality of triangular extensions has at least two curvedsides.
 15. The thermal control module of claim 13, wherein the sleevefully covers each of the plurality of triangular extensions and at leastpartially extends to the first side of the thermal plate forming asleeve spacer in each of the plurality of battery receiving openings.16. The thermal control module of claim 1, wherein the thermal plate andthe first battery engagement component are monolithic.
 17. The thermalcontrol module of claim 1, wherein each of the plurality of batteryreceiving openings is configured to snuggly fit the one of thebatteries.
 18. The thermal control module of claim 1, further comprisinga second battery engagement component, thermally coupled and connectedto the second side of the thermal plate and comprising a secondplurality of battery receiving openings, extending along the third axisof the thermal control module, wherein each of the second plurality ofbattery receiving openings is configured to receive one of thebatteries, such that the second battery engagement component thermallycouples the batteries to the thermal plate, electrically insulates thebatteries from the thermal plate, and fluidically isolates the batteriesfrom the thermal fluid.
 19. The thermal control module of claim 18,wherein: the thermal plate and the first battery engagement componentare monolithic, the thermal plate and the second battery engagementcomponent are monolithic, and the first side and the second side of thethermal plate are joined together thereby forming the interior of thethermal control module.
 20. The thermal control module of claim 18,wherein each of the first battery engagement component and the secondbattery engagement component comprises an insulating coating,electrically insulating the batteries from the thermal plate.